Hyundai 100D-9V Manual
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Hyundai 100D-9V Manual

Hyundai 100D-9V Manual

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Introduction -------------------------------------------------------- 0-2
How to use this manual ------------------------------------- 0-3
EC regulation approved ------------------------------------ 0-5
Safety labels ------------------------------------------------------ 0-6
1. Daily inspection ------------------------------------------- 1-1
2. Do's and don'ts -------------------------------------------- 1-2
3. Seat belt ------------------------------------------------------ 1-4
4. No riders ----------------------------------------------------- 1-5
5. Pedestrians ------------------------------------------------- 1-6
6. Operator protection ------------------------------------- 1-7
7. Fork safety -------------------------------------------------- 1-8
8. Pinch points ------------------------------------------------ 1-9
9. Travel -----------------------------------------------------------
1-10
11. Tip over ------------------------------------------------------- 1-12
12. Surface and capacity ---------------------------------- 1-14
13. Parking -------------------------------------------------------- 1-15
14. Refueling ----------------------------------------------------- 1-16
15. Step ------------------------------------------------------------- 1-17
16. Operator's safety rules -------------------------------- 1-18
1. Loose loads ------------------------------------------------ 2-1
2. Long and wide loads ----------------------------------- 2-2
3. Rear swing -------------------------------------------------- 2-2
4. Low overhead clearance -----------------------------
2-3
5. Fast turns and high loads --------------------------- 2-3
6. Right angle stacking ----------------------------------- 2-4
7. Chain slack ------------------------------------------------- 2-4
8. Pallets and skids ----------------------------------------- 2-5
9. Caution for electrical lines --------------------------- 2-5
10. Lifting loads-------------------------------------------------- 2-6
11. Weight indicator (option) ----------------------------- 2-7
3. KNOW YOUR TRUCK
1. General locations --------------------------------------- 3-1
2. Name plate ------------------------------------------------ 3-2
3. Cab devices ----------------------------------------------- 3-3
4. Cluster -------------------------------------------------------- 3-4
5. Switches ----------------------------------------------------- 3-42
6. Control devices ------------------------------------------ 3-48
7. Air conditioner and heater -------------------------- 3-52
8. Others -------------------------------------------------------- 3-54
9. Regeneration system --------------------------------- 3-74
1. Daily safety inspection ------------------------------- 4-1
2. Suggestion for new truck --------------------------- 4-3
3. Fuel safety practices ---------------------------------- 4-4
1. Before operating the truck ------------------------- 5-1
2. Check before operation ----------------------------- 5-2
3. Check before starting engine --------------------- 5-3
4. Seat adjustment ----------------------------------------- 5-7
5. Starting from a safe condition -------------------- 5-8
7. Starting the engine ------------------------------------- 5-10
8. Check after starting engine ------------------------ 5-11
9. Warming up operation -------------------------------- 5-13
10. Levers and pedals -------------------------------------- 5-14
11. Traveling of the truck ---------------------------------- 5-16
12. Operating safely ----------------------------------------- 5-20
13. Load handling -------------------------------------------- 5-22
14. Shut down procedure -------------------------------- 5-28
15. Storage ------------------------------------------------------ 5-29
16. Transport ---------------------------------------------------- 5-31
CONTENTS
CONTENTS

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  • Page 1: Table Of Contents

    CONTENTS CONTENTS A message to hyundai lift truck operators --------- 0-1 3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK Introduction -------------------------------------------------------- 0-2 1. General locations --------------------------------------- 3-1 How to use this manual ------------------------------------- 0-3 2. Name plate ------------------------------------------------ 3-2 EC regulation approved ------------------------------------ 0-5 3.
  • Page 2 6. EMERGENCY PROCEDURES 6. EMERGENCY PROCEDURES 1. How to tow a disabled truck ------------------------ 6-1 2. Parking brake release --------------------------------- 6-3 3. How to use battery jumper cables -------------- 6-4 4. Emergency fork lowering ---------------------------- 6-6 5. Key-lowering interlock --------------------------------- 6-7 7.

  • Page 4: A Message To Hyundai Lift Truck Operators

    HYUNDAI lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they are only as safe and efficient as the operator and the persons responsible for maintaining them.

  • Page 5: Introduction

    HYUNDAI lift truck in a safe and correct manner. Your HYUNDAI lift truck has been designed and built to be as safe and efficient as today's technology can make it. As manufactured, for some models, it meets all the applicable mandatory requirements of ANSI B56.1-1988 Safety Standard for Powered Industrial Trucks.

  • Page 6: How To Use This Manual

    The descriptions and specifications included in this manual were in effect at the time of printing. HYUNDAI reserves the right to make improvements and changes in specifications or design, without notice and without incurring obligation. Please check with your authorized HYUNDAI dealer for information on possible updates or revisions.
  • Page 7 Acquaint yourself with the various procedures in this manual. Understand how all gauges, indicator lights, and controls function. Please contact your authorized HYUNDAI dealer for the answers to any questions you may have about your lift truck's features, operation, or manuals.

  • Page 8: Ec Regulation Approved

    EC REGULATION APPROVED EC REGULATION APPROVED · Noise level (2000/14/EC and EN 12053) are as followings. Model (EU only) 100D-9V 108 dB 77.3 dB ·The value of vibrations transmitted by the operator's seat are lower than standard value of (2005/88/EC)

  • Page 9: Safety Labels

    36 35 37 28 26 10 38 27 48 29 31 30 18 9 20 17 9ZFJ-00120-04 HYUNDAI logo 18 Model name 32 HYUNDAI logo Mast warning 19 DEF (UREA) 33 Name plate Hand caution 20 Engine room 34 Turbo charger cover...
  • Page 10 2. DESCRIPTION 2. DESCRIPTION There are several specific warning labels on this truck please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. 1) 1) MAST WARNING MAST WARNING (item 2) This label is positioned on the both side of the mast.

  • Page 11: Radiator & Fan

    4) 4) RADIATOR & FAN RADIATOR & FAN (item 5) This label is positioned on the cooling fan shroud of the radiator. It warns of the danger or injury from It warns of the danger or injury from spinning fan blades and forbid so open spinning fan blades and forbid so open the cap of the surge tank because the cap of the surge tank because...

  • Page 12: Diesel Fuel

    6) 6) DIESEL FUEL DIESEL FUEL (item 8) This label is positioned on the top side of the fuel tank. Fill only ultra low sulfer diesel. Fill only ultra low sulfer diesel. ※ Do not fill the gasoline. Do not fill the gasoline. ※...
  • Page 13 8) 8) WARNING SAFETY WARNING SAFETY (item 10) This label is positioned on the top side of LH rear cover of the cabin inside. Refer to operator's manual in detail. ① Always buckle up the seat belt for safety ② operation.

  • Page 14: Tire Pressure

    SOLID TIRE SOLID TIRE (Item 12) This label is located on the right top side of the dashboard. When "solid tires" are equipped. When "solid tires" are equipped. ※ 97HN-00911 Do not travel more than 25 kph (16 mph). Do not travel further than 8 km (5 miles) in an hour.

  • Page 15: Safety Instructions

    SAFETY INSTRUCTION SAFETY INSTRUCTION (item 21) Truck for travel and mast *OPSS This label is positioned on the inside of the SAFETY INSTRUCTIONS rear left side of the cabin if the truck is equipped with *OPSS. This forklift equipped with an operator existence sensing system per ISO 3691 Power travel movement of the truck shall be possible only if the This forklift is equipped with an operator...
  • Page 16 A special air bleed valve is accumulator. A special air bleed valve is necessary for this operation, so please necessary for this operation, so please contact your Hyundai distributor. contact your Hyundai distributor. TILT CABIN WARNING TILT CABIN WARNING (Item 29) This label is positioned on the left side of the frame.
  • Page 17 CABIN TILT LOCK CABIN TILT LOCK (Item 30) This label is positioned on the left side of the frame. Release the cabin tilt lock assembly by turning the tilt lever to the UNLOCK posi- tion before tilting the cabin. Lock the cabin tilt lock assembly by turning the tilt lever to the LOCK position after the cabin original position.
  • Page 18 23 23) CALIFORNIA PROPOSITION CALIFORNIA PROPOSITION (item 36) This label is positioned on the front outside WARNING of the dashboard. CALIFORNIA PROPOSITION 65 Breathing diesel engine exhaust exposes Breathing diesel engine exhaust exposes Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other you to chemicals known to the State of you to chemicals known to the State of...
  • Page 19 26 26) SCR (item 41) This label is located on the rear side of the counterweight. Do not touch the aftertreatment device or Do not touch the aftertreatment device or it may cause severe burn. When the it may cause severe burn. When the engine is running or immediately after engine is running or immediately after engine shut down.

  • Page 20: Guide (Direction, Serial Number, Symbols)

    GUIDE GUIDE 1. DIRECTION 1. DIRECTION The directions of this truck indicate forward, Front backward, right and left when truck is in the travelling direction. Left Right Rear 100D9VSM01 2. SERIAL NUMBER 2. SERIAL NUMBER Inform following when you order parts or the truck is out of order. 1) 1) TRUCK SERIAL NUMBER TRUCK SERIAL NUMBER...

  • Page 21: Safety Hints

    1. SAFETY HINTS 1. SAFETY HINTS 1. DAILY INSPECTION 1. DAILY INSPECTION At the beginning of each shift, inspect your truck and fill out a check, maintenance and lubrication table. Check for damage and maintenance problems. Have repairs made before you operate the truck.

  • Page 22: Do's And Don'ts

    2. DO'S AND DON'TS 2. DO'S AND DON'TS Do watch for pedestrians. D35AOM03 Do wear safety equipment when required. D35AOM05 Do not mix drugs or alcohol with your job. D35AOM02 Do not block safety or emergency equipment. 100D9VOM04 Do not smoke in NO SMOKING areas or when refueling. D35AOM06...
  • Page 23 Do not operate the truck outdoors in rainy day. ※Exclude the truck equipped cabin. Exclude the truck equipped cabin. 100D9VOM07 Exhaust gas is dangerous. Do not operate the truck at the inhouse, if possible. Provide adequate ventilation when working in a closed space. 100D9VOM08...

  • Page 24: Seat Belt

    3. SEAT BELT 3. SEAT BELT Always buckle up for the truck equipped Always buckle up for the truck equipped with safety belt. with safety belt. 22D9TOM09 Seat belts can reduce injuries. Seat belts can reduce injuries. 22D9TOM10...

  • Page 25: No Riders

    4. NO RIDERS 4. NO RIDERS The operator is the only one who should be on a truck. 100D9VOM12 Never transport personnel on the forks of a lift truck. 100D9VOM14...

  • Page 26: Pedestrians

    5. PEDESTRIANS 5. PEDESTRIANS Watch where you are going. Look in the direction of travel. Pedestrians may use the same roadway you do. Sound your horn at all intersections or blind spots. 100D9VOM05 Watch for people in your work area even if your truck has warning lights or alarms.

  • Page 27: Operator Protection

    6. OPERATOR PROTECTION 6. OPERATOR PROTECTION Stay inside the cabin. Always keep your body within the confines of the truck. Do not operate truck without cabin or Do not operate truck without cabin or o v e r h e a d g u a r d , u n l e s s c o n d i t i o n o v e r h e a d g u a r d , u n l e s s c o n d i t i o n prevent use of it.

  • Page 28: Fork Safety

    7. FORK SAFETY 7. FORK SAFETY Never allow anyone to walk under raised forks. D255OM17A There is special equipment to raise people for overhead work. DO NOT USE LIFT TRUCKS. 100D9VOM16 Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).

  • Page 29: Pinch Points

    8. PINCH POINTS 8. PINCH POINTS Keep hands, feet and legs out of the Keep hands, feet and legs out of the mast. mast. D255OM61 Do not use the mast as a ladder. Do not use the mast as a ladder. 100D9VOM62 Never try to repair the mast, carriage, Never try to repair the mast, carriage,...

  • Page 30: Travel

    9. TRAVEL 9. TRAVEL Travel with the load near the floor and the ground, with mast tilted back to cradle the load whenever possible. Never lift or lower the load when the Never lift or lower the load when the truck is in motion.

  • Page 31: Grades, Ramps, Slopes, And Inclines

    10. GRADES, RAMPS, SLOPES, AND INCLINES 10. GRADES, RAMPS, SLOPES, AND INCLINES Never turn on a grade, either loaded or unloaded. Never turn on a grade, either loaded or unloaded. Unloaded-Forks downgrade 100D9VOM30 Loaded - Forks upgrade 100D9VOM33 1-11...

  • Page 32: Tip Over

    11. TIP OVER 11. TIP OVER 1) 1) LATERAL TIP OVER LATERAL TIP OVER L a t e r a l t i p o v e r c a n o c c u r w i t h a combination of speed and sharpness of turn.
  • Page 33 3) 3) WHAT TO DO IN CASE OF A TIP OVER WHAT TO DO IN CASE OF A TIP OVER If your truck starts to tip over, do not If your truck starts to tip over, do not jump. jump. Brace yourself as illustrated right.

  • Page 34: Surface And Capacity

    12. SURFACE AND CAPACITY 12. SURFACE AND CAPACITY Avoid these conditions. They can cause a truck to tip over or lose traction for braking or driving. Know the weight of your truck and load. Know the weight of your truck and load. Especially when using elevators, know Especially when using elevators, know the capacity of the elevator you intend to...

  • Page 35: Parking

    13. PARKING 13. PARKING Never park on a grade. 100D9VOM41 Always come to a complete stop before leaving the truck. Be sure the travel control is in NEUTRAL. 100D9VOM42 Lower forks fully to floor and tilt forward. 100D9VOM43 Set the parking brake. Position 1 : Release Position 2 : Lock Turn key to OFF position.

  • Page 36: Refueling

    14. REFUELING 14. REFUELING Before adding oil, check around the truck for oil leakage. 100D9VOM47 Keep away from fire when adding oil or during operation. 100D9VOM48 After adding oil, wipe off any oil spilled on the truck. 100D9VOM49 1-16...

  • Page 37: Step

    15. STEP 15. STEP When getting on or off the truck, use the step provided. 100D9VOM50 Do not jump up or down from the truck. 100D9VOM51 1-17...

  • Page 38: Operator's Safety Rules

    16. OPERATOR'S SAFETY RULES 16. OPERATOR'S SAFETY RULES All operational functions require that the operator be seated in the operator's seat. Al w ays bu ckl e up i f a seat be l t i s Always buckle up if a seat belt is provided.

  • Page 39: Side Shift And Fork Positioner (Option)

    17. SIDE SHIFT AND FORK POSITIONER (OPTION) SIDE SHIFT AND FORK POSITIONER (OPTION) Do not put side loads on the forks. Do not put side loads on the forks. 100D9V1SS01 Restrict the sideshift movement with Restrict the sideshift movement with raised load.
  • Page 40 Never operate the side shift while the forks are not equipped with supports such as a load table for the load. Never travel the forklift while the side shift is moved with load. In case of moving the side shift with load, it can be caused load dropping or overturning of the forklift due to unbalanced weight.
  • Page 41 Do not operate the fork positioner with a load, or with the fork arm on the ground. Never move the levers to operate the Never move the levers to operate the fork positioner suddenly and quickly. fork positioner suddenly and quickly. It can be caused to drop the load.

  • Page 42: Operating Hazards

    2. OPERATING HAZARDS 2. OPERATING HAZARDS 1. LOOSE LOADS 1. LOOSE LOADS L o o s e o r u n b a l a n c e d l o a d s a r e L o o s e o r u n b a l a n c e d l o a d s a r e dangerous.

  • Page 43: Long And Wide Loads

    2. LONG AND WIDE LOADS 2. LONG AND WIDE LOADS With long or wide loads, you need more With long or wide loads, you need more room. So slow down and watch your room. So slow down and watch your clearance.

  • Page 44: Low Overhead Clearance

    4. LOW OVERHEAD CLEARANCE 4. LOW OVERHEAD CLEARANCE Know the height of your truck, with and Know the height of your truck, with and without a load. Check your clearances. without a load. Check your clearances. Keep the load low and tilted back. Keep the load low and tilted back.

  • Page 45: Right Angle Stacking

    6. RIGHT ANGLE STACKING 6. RIGHT ANGLE STACKING When right angle stacking or moving with When right angle stacking or moving with a raised load to clear low objects, avoid a raised load to clear low objects, avoid sharp turns and move slowly. sharp turns and move slowly.

  • Page 46: Pallets And Skids

    8. PALLETS AND SKIDS 8. PALLETS AND SKIDS Do not move or store materials on Do not move or store materials on damaged pallets or skids. Items can fall damaged pallets or skids. Items can fall through them causing severe injury or through them causing severe injury or death.

  • Page 47: Lifting Loads

    10. LIFTING LOADS 10. LIFTING LOADS Never permit any persons to stand or pass under lifted load. D255OM17A Never use wire rope to lift a load. 100D9VOM60...
  • Page 48 11. FORK POSITIONER 11. FORK POSITIONER Do not operate the fork positioner with a load, or with the fork arm on the ground. Never move the levers to operate the Never move the levers to operate the fork positioner suddenly and quickly. fork positioner suddenly and quickly.

  • Page 49: Weight Indicator (Option)

    13. WEIGHT INDICATOR (OPTION) 13. WEIGHT INDICATOR (OPTION) · This device is a convenience feature that shows the weight of the load lifted by the fork. If the weight of the load exceeds the truck's rated capacity, a warning tone can be used to check the truck's overload in advance.

  • Page 50: Know Your Truck

    3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 1. GENERAL LOCATIONS 100D9V3CD10 Mast Rear view mirror 15 Beacon lamp (option) Lift chain Rear wheel 16 Camera (option) Lift cylinder 10 Body wing cover 17 Silencer Carriage and backrest 11 Rear combination lamp 18 Rear work lamp Tilt cylinder...

  • Page 51: Name Plate

    TRUCK SERIAL NUMBER An identification number assigned to this particular truck and should be used when requesting information or ordering service parts for this truck from your authorized HYUNDAI dealer. The serial number is also stamped on the frame. 4) 4)

  • Page 52: Cab Devices

    3. CAB DEVICES 3. CAB DEVICES The ergonomically designed console box and suspension type seat provide the operator with comfort. 2) 2) ELECTRONIC MONITOR SYSTEM ELECTRONIC MONITOR SYSTEM The centralized electronic monitor system allows the status and conditions of the truck to be monitored at a glance.

  • Page 53: Cluster

    4. CLUSTER CLUSTER STRUCTURE Like following figure, cluster is consisted of LCD and buttons. LCD will indicate the operation and abnormal status of truck to the driver in order to use and maintenance. Also, LCD allows to set and indicate the various modes, monitoring, and gadgets. The cluster installed on this truck does not entirely guarantee the condition of the truck.
  • Page 54 2) 2) GAUGE GAUGE Operation screen Operating screen will be displayed if turn on the start switch. 70D9V3KY30A Speed meter Coolant temperature gauge Transmission oil temperature gauge Fuel gauge DEF gauge Clock Speed meter It indicates the speed of truck and calibrated in miles per hour ·...
  • Page 55 (5) (5) DEF (Diesel Exhaust Fluid) gauge DEF (Diesel Exhaust Fluid) gauge This gauge indicates the level of DEF. · Fill the DEF when the level is low. · 70D9V3KY33 (6) (6) Transmission oil temperature gauge Transmission oil temperature gauge This range indicates the temperature of transmission oil.

  • Page 56: Warning Lamps

    3) 3) WARNING LAMPS WARNING LAMPS 70D9V3KY35 Warning and indicator lamp will display only items that were set as ON, and all warning and Warning and indicator lamp will display only items that were set as ON, and all warning and ※...
  • Page 57 (1) (1) Fuel level warning lamp Fuel level warning lamp Warning lamp will be displayed if fuel level is low. · Please refuel immediately if the lamp is ON. · 35L93KY155 (2) (2) Coolant temperature warning lamp Coolant temperature warning lamp Coolant temperature warning will be lit up when temperature is ·...
  • Page 58 Engine stop warning lamp If the lamp lights on, stop the engine immediately and check the · engine. Please contact your Hyundai service center or local dealer. Please contact your Hyundai service center or local dealer. ※ 35D9VB3KY15 (8) (8)
  • Page 59 (11) (11) Communication error warning lamp Communication error warning lamp This warning lamp will be lit up if the communication between · cluster-CI and ECU is fail. Please check the communication line if the warning lamp is lit up. · 35D9VB3KY20 (12) (12)
  • Page 60 1. These lamps will be on when a manual (stationary) exhaust system cleaning is not performed 2. Stop the engine immediatary 3. Please contact your hyundai service center or local dealer The status of a manual (stationary) exhaust system cleaning when Flash the exhaust system cleaning switch has been activated.
  • Page 61 Manual exhaust system cleaning Manual exhaust system cleaning ※ Manual exhaust system cleaning must be operated in a Manual exhaust system cleaning must be operated in a ※ fireproof area. fireproof area. To stop a manual exhaust system cleaning before it has To stop a manual exhaust system cleaning before it has ※...
  • Page 62 When this warning lamp lights ON, stop the engine immediately · and and check the DEF level and related parts of the engine. Please contact your Hyundai service center or local dealer. Please contact your Hyundai service center or local dealer. ※...
  • Page 63 (21) (21) Transmission warning lamp Transmission warning lamp If the lamp lights on, check the transmission. · If the red warning light is lit while driving, stop the engine and · check the forklift. 70D9V3KY194 (22) (22) Seat belt reminder lamp Seat belt reminder lamp This lamp will be blinked 5 times, after key on.

  • Page 64: Indicator Lamps

    4) 4) INDICATOR LAMPS INDICATOR LAMPS 70D9V3KY36 Warning and indicator lamps will display only items that were set as ON, and all warning and Warning and indicator lamps will display only items that were set as ON, and all warning and ※...
  • Page 65 (1) (1) Consumables management indicator lamp Consumables management indicator lamp Light up if consumables which must be replaced are exist. · The indicator lamp will light up only 3 minutes since start switch · ON, and then light OFF. Please check the consumables management list in maintenance ·...
  • Page 66 (6) (6) OPSS indicator lamp OPSS indicator lamp Light up if driver leave seat during operation. · Truck driving and/or mast control will be blocked if lamp is lit up. · Please refer to page 0-12 for details. Please refer to page 0-12 for details. ※...
  • Page 67 (10) (10) High beam indicator lamp High beam indicator lamp This indicator is displayed when the vehicle's high beam is on. · 70D9V3KY196 (11) (11) Shift mode indicator lamp 1 Shift mode indicator lamp 1 This indicator shows the current vehicle's shift mode, A1 and A2 ·...

  • Page 68: Information Display

    5) 5) INFORMATION DISPLAY INFORMATION DISPLAY Truck front/rear tilt Load weight Operation time Total trip distance Truck left/right tilt 70D9V3KY40 (1) (1) Mast front/rear tilt Mast front/rear tilt Display the real time tilt of mast. · 70D9V3KY41 (2) (2) Truck front/rear tilt Truck front/rear tilt Display the front and rear tilt of truck in real time.
  • Page 69 (4) (4) Load weight Load weight (option) Display the load weight. · Screen will display blurry if the weight sensor has not been · mounted. 35D9VB3KY38 (5) (5) Total trip distance Total trip distance Display total trip distance of the truck. ·...
  • Page 70 6) 6) BUTTONS BUTTONS (1) (1) Camera Camera This switch displays rear camera images. (if the camera is · mounted) 35D9VB3KY41 (2) (2) UP/Left UP/Left This switch is used to move upward or leftward in menu or · increase the value. 35D9VB3KY42 (3) (3) Down/Right...
  • Page 71 7) 7) MAIN MENU MAIN MENU (1) (1) Structure Structure Menus consist of main menu and sub-menu. Operation Screen Main Menu Screen Sub-Menu Screen 70D9V3KY42 Main menu screen Sub menu Explanation Model select Diesel, LPG · · Tilt setting Truck tilt initialize ·...
  • Page 72 (2) (2) Equipment menu Equipment menu Model Select (a required setting) Model Select (a required setting) ① Check under the start switch ON status. Selection will be canceled if press the cancel button. This is a required setting. Some functions may not be worked properly if you do not select This is a required setting.
  • Page 73 Tilt Setting Tilt Setting ② Setting Setting (Check under the start switch ON status.) (Check under the start switch ON status.) The tilt sensor has already been initialized when deliver the truck from factory. The tilt sensor has already been initialized when deliver the truck from factory. ※...
  • Page 74 d) d) Left or right truck tilt warning (red) Left or right truck tilt warning (red) · Stop : ±3.4°(1.5 ~ 5.0 tons) Driving · Truck weight Warning angles (red) 1.5 ~ 2.0 tons ° ±20.3 2.2 ~ 3.3 tons °...
  • Page 75 b. b. Check functions Check functions Set the mode as active and start switch OFF. Upon start switch ON, the password screen pops up and starting is prohibited until the right. password has been offered. (But, driver still can start the vehicle if starts within 10 seconds from start switch OFF) Set the mode as 5 min of delay time and start switch OFF.
  • Page 76 Cylinder cross-section value Cylinder cross-section value unit : cm Model Mast type V-mast TS-mast V300~500 113.49 141.76 TS450~500 100D-9V V550~600 141.76 190.07 TS550~750 · · Truck that has not applied the Truck that has applied the weight weight sensor sensor (option) 70D9V3KY53 1.
  • Page 77 b. b. Unloaded status adjustment Unloaded status adjustment 1. Equipment 2. Password 3. Weight Sensor Setting 70D-9V 35D9VB3KY47 35D9VB3KY51 70D9V3KY56 Enter to Equipment menu Enter the password Choose Weight Sensor Setting 4. Load Weight Adjustment 5. Unloaded Status Adjustment 6. Instruction 70D9V3KY59 70D9V3KY60 35D9VB3KY71...
  • Page 78 c. c. Loaded status adjustment Loaded status adjustment Must be prepared to lift up by locating the load on the fork before enter the weight. Must be prepared to lift up by locating the load on the fork before enter the weight. ※...
  • Page 79 d. d. Reset Reset Initialize the all values of 'Unloaded and Loaded Status Adjustment' that were entered previously. (Cylinder cross-sectional area is not initialized.) 1. Equipment 2. Password 3. Weight Sensor Setting 70D-9V 35D9VB3KY47 35D9VB3KY51 70D9V3KY56 Enter to Equipment menu Enter the password Choose Weight Sensor Setting...
  • Page 80 e. e. Weight Display Setting Weight Display Setting Enable to adjust the digit-number fo weight of main screen. 1. Equipment 2. Password 3. Weight Sensor Setting 70D-9V 35D9VB3KY47 35D9VB3KY51 70D9V3KY56 Enter to Equipment menu Enter the password Choose Weight Sensor Setting 4.
  • Page 81 f. f. Overload Alarm Overload Alarm 1. Equipment 2. Password 3. Weight Sensor Setting 70D-9V 35D9VB3KY47 35D9VB3KY51 70D9V3KY56 Enter to Equipment menu Enter the password Choose Weight Sensor Setting 4. Overload alarm 5. Select 6. Completion 70D9V3KY68 35D9VB3KY81 100D9VB3KY80 Enter to Overload alarm. Select ON or OFF.
  • Page 82 FingerTips FingerTips Setting Setting (option) (option) ⑥ 1. Equipment 2. Password 3. FingerTips Setting 35D9VB3KY47 35D9VB3KY51 70D9V3KY72 Enter to Equipment. Enter the password Choose FingerTips Setting and enter. a. a. Lever Position Setting Lever Position Setting 1. Lever Position Setting 2.
  • Page 83 CSC (Curve Speed Control) Setting (if installed) CSC (Curve Speed Control) Setting (if installed) ⑦ 1. Equipment 2. Password 3. CSC Setting 35D9VB3KY47 35D9VB3KY51 70D9V3KY80 Enter to Equipment. Enter the password Choose CSC setting and enter. 4. Select 5. Completion 70D9V3KY81 70D9V3KY82 Select ON or OFF.
  • Page 84 b. b. Speed Setting Speed Setting In case of 1st gear → 2nd gear, it is possible to set up to 7 ~ 10 km/h. · In case of 2nd gear → 1st gear, it is possible to set up to 4 ~ 5 km/h. ·...
  • Page 85 HAC (Hill Assist Control) Setting (if installed) (Hill Assist Control) Setting (if installed) ⑩ If you are trying to drive in stop status on the hill, the truck does not move backward when the HAC setting is ON. 1. Equipment 2.
  • Page 86 Zero Start Setting (if installed) Zero Start Setting (if installed) ⑫ 1. Equipment 2. Password 3. Zero Start Setting 35D9VB3KY47 35D9VB3KY51 70D9V3KY98 Enter to Equipment. Enter the password Choose Zero Start Setting and enter. 4. Select Sensitivity 5. Setting Sensitivity 100D9V3KY99 100D9V3KY10 Change value using up/down...
  • Page 87 ZF TCU ZF TCU Calibration Calibration ⑭ Enable to calibrate the inching and clutch of the transmission. Depending on the model, the initial conditions for calibration may be different or the procedure Depending on the model, the initial conditions for calibration may be different or the procedure ※...
  • Page 88 b. b. Clutch Calibration Clutch Calibration 2-1. ZF TCU Calibration 2. Password 3. ZF TCU Calibration 70D9V3KY127 35D9VB3KY51 70D9V3KY127 Choose ZF TCU Calibration Enter the password Choose ZF TCU Calibration and enter. and enter. 4. Prepare for Calibration ※ Conditions Conditions 1) Engine RPM 800 to 1100 2) T/M temperature 60℃...
  • Page 89 Seat Belt Interlock (option) Seat Belt Interlock (option) ⑮ 1. Equipment 2. Password 3. Seat Belt Interlock 35D9VB3KY47 35D9VB3KY51 70D9V3KY132 Enter to Equipment. Enter the password (applied Choose Seat Belt Interlock master password) and enter. 4. Select 5. Completion 70D9V3KY133 70D9V3KY134 Setting has been completed.

  • Page 90: Maintenance

    (2) (2) Maintenance Maintenance Failure History ailure History ① 1. Maintenance 2. Password 3. Failure History 35D9VB3KY48 35D9VB3KY51 70D9V3KY138 Enter to Maintenance. Enter the password Choose Failure History and enter. 4. Engine or Transmission 5. History 6. Failure List 70D9V3KY139 70D9V3KY140 70D9V3KY141 Choose what needs to...
  • Page 91 7. Replacement 8. Confi rm 9. Change 70D9V3KY146 70D9V3KY147 70D9V3KY148 Select Replacement. Press enter button. Select Change. 10. Setting Cycle 11. Completion 70D9V3KY149 70D9V3KY150 C h a n g e p r o p e r l y t h e Setting has been completed.
  • Page 92 (3) (3) Display setting Display setting LCD Brightness Adjustment rightness Adjustment ① LCD brightness has two options. (Automatic and Manual modes) · Manual mode always keeps the selected brightness. · Brightness : Daytime 100%, Nighttime 50% · Daytime/Nighttime time zone : 06 ~ 18 ·...
  • Page 93 b. b. Unit Setting Unit Setting 1. Unit Setting 2. Unit Setting Litst 3. Setting 70D9V3KY159 35D9VB3KY152 35D9VB3KY153 Select Unit Setting. Enable to set the unit of Set unit. speed, weight, temperature and pressure. c. c. Language Setting Language Setting 1.
  • Page 94 Password Change. Password Change. ④ This function is to allow to change password from default password to user defined password. · Password length must be 5~10 digits. · Since, if you forget the password, you must request the A/S, do not forget the password. Since, if you forget the password, you must request the A/S, do not forget the password.
  • Page 95 Consumables M Consumables Management anagement ⑤ 1. Display Setting 2. Conusmables Management 3. List 35D9VB3KY49 70D9V3KY174 70D9V3KY143 Enter to Display Setting. Choose Consumables Man- agement and enter. 8) 8) CAUSES AND CORRECTION OF CLUSTER WARNING LAMP CAUSES AND CORRECTION OF CLUSTER WARNING LAMP Warning lamp types Symbol Warning and indicator lamp...
  • Page 96 Warning lamp types Symbol Warning and indicator lamp Causes and correction Battery charging Battery charging warning Battery is not being charged. warning lamp Please check alternator and wiring. Tilt lock indicator Tilt lock indicator lamp Auto-leveling is the operational status. (if installed) OPSS is working : 15 OPSS indicator...

  • Page 97: Switches

    5. SWITCHES 5. SWITCHES In/decrement switch Regeneration switch Inching switch Rear wiper/washer switch Power switch Hazard switch (opt) Auto shift switch Parking brake switch Rear work lamp switch Top wiper/wahser switch (opt) Heated mirror switch (opt) Main light switch Fuel warmer switch Cover Multi function switch Horn button...

  • Page 98: Start Switch

    START SWITCH START SWITCH There are three positions, OFF, ON and START. (OFF) : Position to stop the engine. Insert or remove the · ignition key from this position. (ON) : The operation of the electrical device. It is located ·...

  • Page 99: Power Switch

    5) 5) POWER SWITCH POWER SWITCH This switch offers two selectable operating mode. The operator can adjust the truck's performance with this selection switch. (2) (2) Function Function STD MODE ① This mode provides maximum fuel efficiency for general loading. 70D9V3KY04 PWR MODE ②...
  • Page 100 9) 9) EXHAUST SYSTEM CLEANING SWITCH EXHAUST SYSTEM CLEANING SWITCH This switch is used to select the cleaning function of the exhaust system. (2) (2) Inhibit position ( Inhibit position (①) The inhibit position disallows any automatic or manual exhaust ①...

  • Page 101: Horn Button

    TOP WIPER AND WASHER SWITCH (OPTION) TOP WIPER AND WASHER SWITCH (OPTION) This switch is used to operate the wiper and washer on the top of the cab. The washer liquid is sprayed and the wiper is operated only while pressing this switch.
  • Page 102 MASTER SWITCH MASTER SWITCH (option) This switch is used to shut off the entire electrical system. When the machine is not operated for a long time, turn OFF the master switch for the safety purpose. I : The battery remains connected to the electrical system. O : The battery is disconnected to the electrical system.
  • Page 103 FUEL WARMER SWITCH FUEL WARMER SWITCH This switch is used to heat the fuel of pre-heater. 35D9AOM19 FNR ENABLE SWITCH FNR ENABLE SWITCH (option) This switch makes FNR to enable when the fingertip is equipped as an option. 160D9V3CD66 FNR SWITCH FNR SWITCH (option) This switch changes travel direction of truck only when the FNR enable switch is selected ON.

  • Page 104: Control Devices

    6. CONTROL DEVICE 6. CONTROL DEVICES Aux 1, 2, 3 lever (opt) Tilt lever Lift lever Steering handle Gear selector lever Accelerator pedal Brake pedal Inching pedal Fingertip type (opt) Lift lever Tilt lever Aux 1, 3 lever (opt) Aux 2 lever (opt) 100D9V3KY04 1) 1) LIFT LEVER...
  • Page 105 2) 2) TILT LEVER TILT LEVER (1) (1) TILT FORWARD TILT FORWARD Lever type PUSH the lever FORWARD to tilt mast FORWARD. Tilt forward (2) (2) TILT BACKWARD TILT BACKWARD PULL the lever BACK to tilt mast BACKWARD. (3) (3) HOLDING HOLDING Tilt...
  • Page 106 4) 4) LEVER FOR SIDE SHIFT WITH FORK POSITIONER LEVER FOR SIDE SHIFT WITH FORK POSITIONER FORK POSITIONER (SYNCHRONIZER TYPE) FORK POSITIONER (SYNCHRONIZER TYPE) OPEN THE FORKS OPEN THE FORKS ① Lever type Push the lever forward to open both forks simultaneously. Open CLOSE THE FORKS CLOSE THE FORKS...

  • Page 107: Gear Selector Lever

    RH FORK MOVEMENT RH FORK MOVEMENT ② Lever type - Push the lever forward to move the RH fork outward. Outward - Pull the lever backward to move the RH fork inward. Operate the aux 2 lever while holding down the aux 3 mode Operate the aux 2 lever while holding down the aux 3 mode ※...

  • Page 108: Accelerator Pedal

    7) 7) ACCELERATOR PEDAL ACCELERATOR PEDAL This pedal controls the engine speed. The engine speed will increase in proportion to the degree of force applied to this pedal. Unless this pedal is pressed, the engine will run at low idling. 70D9V3KY07 8) 8) BRAKE PEDAL...

  • Page 109: Air Conditioner And Heater

    7. AIR CONDITIONER AND HEATER 7. AIR CONDITIONER AND HEATER Full auto air conditioner and heater are equipped for pleasant operation against outside temperature and defrost on window glass. Air conditioner button Air inlet control button Air outlet control knob Temperature control button Fan speed control knob Air conditioner and heater controller...
  • Page 110 4) 4) AIR INLET CONTROL BUTTON AIR INLET CONTROL BUTTON This button regulates the inlet air. Pilot lamp ON : Fresh air intake. ① Pilot lamp OFF : The air circulates in the cab. ② The pilot lamp is turned ON when the button is pushed. The pilot lamp is turned ON when the button is pushed.
  • Page 111 Error Meaning Ambient sensor open 1. Check assembly status. Ambient sensor short 2. Ambient temperature sensor exchange after single item check. In-cabin temperature sensor open 1. Check assembly status. In-cabin temperature sensor short 2. In-cabin temperature sensor exchange after single item check. Evap.

  • Page 112: Others

    8. OTHERS 8. OTHERS Radio and USB player (opt) Authentication device (opt) Camera monitor (opt) Cluster USB charger 12 V socket 100D9V3KY13 12V SOCKET 12V SOCKET Utilize the power of 12 V as your need and do not exceed power of 12 V, 120 W.
  • Page 113 3) 3) TRANSMISSION CONTROL UNIT TRANSMISSION CONTROL UNIT (TCU) The control unit is shifting the required speeds fully-automatically under consideration of the following criteria. · Gear selector lever position · Driving speed · Load level 160D9V3CD92 4) 4) ENGINE CONTROL MODULE ENGINE CONTROL MODULE (ECM) The engine control module (ECM) is the control center of the engine system.
  • Page 114 RADIO AND USB PLAYER (WITH BLUETOOTH, OPTION) RADIO AND USB PLAYER (WITH BLUETOOTH, OPTION) 9403CD100 ■FRONT PANEL PRESENTATION FRONT PANEL PRESENTATION -------- Power ON/OFF, ------- Station preset 5 Volume UP/DOWN button DIR- ----------- Directory down button -------- Manual UP/DOWN Tuning, -------- Station preset 6 File search, SEL button DIR+ ---------- Directory up button...
  • Page 115 RADIO AND USB PLAYER (WITHOUT BLUETOOTH, OPTION) RADIO AND USB PLAYER (WITHOUT BLUETOOTH, OPTION) 9403CD101 ■FRONT PANEL PRESENTATION FRONT PANEL PRESENTATION -------- Power ON/OFF, ------- Station preset 5 Volume UP/DOWN button DIR- ----------- Directory down button -------- Manual UP/DOWN Tuning, ------- Station preset 6 File search, SEL button DIR+ ----------- Directory up button...
  • Page 116 GENERAL ■GENERAL (1) (1) Power and volume button Power and volume button Power ON / OFF Power ON / OFF button button ① Press power button (1) to turn the unit on or off. Volume Volume UP/DOWN UP/DOWN control knob control knob ②...
  • Page 117 (2) (2) Menu Selection Menu Selection This button can adjust the effect of the sound and other things. ① Each time you press this button (2), LCD displays as follows : TREB BAL L=R FAD F=R LOUD ON BEEP 2ND On each setting, the level can be controlled by turning TUNE knob (2).
  • Page 118 Loud control Loud control ⑦ When listening to music at low volume levels, this feature will boost the bass and treble response. This action will compensate for the reduction in bass and treble performance experienced at low volume. To select the loudness feature, press button (2) until LOUD is displayed, then turn knob (2) right or left to activate or deactivate loudness.
  • Page 119 RADIO ■RADIO (1) (1) Mode button Mode button Repeat press MODE button to select FM1, FM2 or AM. ① 9403CD104 (2) (2) Manual tuning button Manual tuning button To manually tune to a radio station, simply turn encoder TUNE (2) ①...
  • Page 120 (5) (5) Preset scan (PS) / Best station memory (BSM) button Preset scan (PS) / Best station memory (BSM) button Press BSM button (12) momentarily to scan the 6 preset stations ① stored in the selected band. When you hear your desired station, press it again to listen to it.
  • Page 121 ■USB PLAYER USB PLAYER (1) (1) USB playback USB playback ① The unit was equipped with a front USB jack and also a rear USB Jack. With a USB device plugged in the front USB jack, it will be detected as front USB mode.
  • Page 122 (5) (5) Track Scan Play (SCAN) button Track Scan Play (SCAN) button SCAN playback : Simply press SCAN (12) button to play the first 10 seconds of each track. SCAN folder : Press and hold SCAN button for longer than 2 seconds to scan play the tracks in current folder.
  • Page 123 ■AUX OPERATION AUX OPERATION It is possible to connect your portable media player to the audio system for playback of the audio tracks via the cab speakers. To get the best results when connecting the portable media to the audio system, follow these steps : Use a 3.5 mm stereo plug cable to connect the media player headphone socket at each end as follows.
  • Page 124 BLUETOOTH (if equipped) ■BLUETOOTH (1) (1) Using a bluetooth wireless connection Using a bluetooth wireless connection Your audio unit supports bluetooth wireless technology. You can set up a wireless link with ① bluetooth cellular phone. Continue to pair the cellular phone with the audio unit. Within a few moments the two should be ②...
  • Page 125 Please retry the pairing instruction if HYUNDAI does not appear on the cellular phone screen. Please retry the pairing instruction if HYUNDAI does not appear on the cellular phone screen.
  • Page 126 (4) (4) Bluetooth connection and disconnection Bluetooth connection and disconnection When established bluetooth connection is made between this audio ① unit and the cellular phone, bluetooth icon on the display appears and then the display shows HF/AV CONN when handsfree & AV profile is connected.
  • Page 127 (6) (6) Audio transfer between the audio unit and phone Audio transfer between the audio unit and phone The audio transfer function is for switching the call from the audio unit to the cellular phone for private conversation. Press CALL button (4) briefly during conversation, it appears CALL ①...
  • Page 128 (9) (9) Using the audio unit as bluetooth music Using the audio unit as bluetooth music The audio unit supports A2DP (Audio Advanced Distribution Profile) and AVRCP (Audio Video Remote Control Profile), and both profiles are available to listen music at the audio unit via cellular phone which is supporting the two profiles above.
  • Page 129 ■RESET AND PRECAUTIONS RESET AND PRECAUTIONS Reset function Reset function Interfering noise or abnormal compressed files in the MP3 disc or USB instrument may cause intermittent operation (or unit frozen/locking up). It is strongly recommended to use appropriate USB storage to not cause any malfunction to the audio unit. In the unlikely event that the player fails to operate correctly, try to reset unit by any of following two methods.

  • Page 130: Camera Monitor

    8) 8) CAMERA MONITOR CAMERA MONITOR (option) (option) 960A3CD65 (1) Summary of key actions Summary of key actions Function menu Button Description Single Cam mode - Single Cam - Beep stop* POWER - Beep stop* - Menu escape (save & exit) - 0 : Menu select SELECT Parking guide line On / Off...
  • Page 131 (2) Operation scenario (Single camera mode) (2) Operation scenario (Single camera mode) 160D9V3CD100 3-82...
  • Page 132 (3) Function menu tree (Single cam mode) (3) Function menu tree (Single cam mode) 160D9V3CD101 3-83...
  • Page 133 (4) Parking guide line adjust (4) Parking guide line adjust 160D9V3CD102 3-84...
  • Page 134 (5) How to set function menu (5) How to set function menu 160D9V3CD103 3-85...
  • Page 135 (6) Composition of menu screen (6) Composition of menu screen 160D9V3CD104 3-86...
  • Page 136 (7) Value adjustment (7) Value adjustment 160D9V3CD105 3-87...
  • Page 137 9) 9) HI-MATE (BASIC) HI-MATE (BASIC) (1) (1) How to connect How to connect ① Web : https://himate.hyundai-ce.com 92FT-00426 ② App : iOS App Store / Google Play Store Search “HiMATE 160D9V3HM02 3-88...
  • Page 138 (2) (2) How to search How to search ① You can search, see the result and get additional valuable information at a glance. 160D9V3HM03 ② You can search, see the result and get additional valuable information at a glance. 160D9V3HM04 3-89...
  • Page 139 ③ After you click the search button, the location (map) and list of the devices that appear as search results appear. The equipment is expressed in green, sky blue, purple, depending on the type. 160D9V3HM05 ④ The icon of the map refers to different types of equipment by color. 160D9V3HM06 3-90...
  • Page 140 (3) (3) How to search machine list How to search machine list When you click S/N in the list, the details of appliance will be displayed, and when you click the location, the map screen moves to the location of the equipment. 160D9V3HM07 (4) (4) How to create fleet...
  • Page 141 (5) (5) Application list Application list 160D9V3HM09 (6) (6) Extension of service Extension of service 160D9V3HM10 3-92...
  • Page 142 (7) (7) Machine details (engine type) Machine details (engine type) In the working status, you can find more information, including operation information, alarm, and etc. 160D9V3HM11 (8) (8) Machine details (electric type) Machine details (electric type) In the working status, you can find more information, including operation information, alarm, and etc.
  • Page 143 (9) (9) Load and angle sensor (EH) Load and angle sensor (EH) 9Ser. All FEH01 Load Sensor Load Sensor + Angle Sensor 16~30ton FEH03 (option) (option) 160D9V3HM34A 3-94...
  • Page 144 (10) (10) Machine details (monthly period) Machine details (monthly period) Can check the operating history, temperature distribution, and fuel usage. 160D9V3HM13 (11) (11) Alarm Alarm 160D9V3HM14 3-95...
  • Page 145 (12) (12) Geo-fencing Geo-fencing 160D9V3HM15 (13) (13) Alarm Alarm 160D9V3HM16 3-96...
  • Page 146 (14) (14) Hourmeter Hourmeter 160D9V3HM17 (15) (15) Temperature (available in dealer accounts) Temperature (available in dealer accounts) 160D9V3HM18 3-97...
  • Page 147 (16) (16) MCU information (available in dealer accounts) MCU information (available in dealer accounts) 160D9V3HM19 (17) (17) Running history (available in dealer accounts) Running history (available in dealer accounts) 160D9V3HM20 3-98...
  • Page 148 (18) (18) Mobile app Mobile app 160D9V3HM21 3-99...
  • Page 149 HI-MATE (PREMIUM) HI-MATE (PREMIUM) (1) (1) Brief benefit Brief benefit 160D9V3HM22 (2) (2) How to access menu How to access menu 160D9V3HM23 3-100...
  • Page 150 (3) (3) Manage sites Manage sites 160D9V3HM24 (4) (4) Manage drivers (use pin number) Manage drivers (use pin number) 160D9V3HM25 3-101...
  • Page 151 (5) (5) Manage drivers (use RFID number) Manage drivers (use RFID number) 160D9V3HM26 (6) (6) How to register a driver to use the equipment How to register a driver to use the equipment 160D9V3HM27 3-102...
  • Page 152 (7) (7) How to check driver information in the authentication device How to check driver information in the authentication device 160D9V3HM28 (8) (8) Manage pre-check Manage pre-check 160D9V3HM29 3-103...
  • Page 153 (9) (9) Manage collision and over speed Manage collision and over speed 160D9V3HM30 (10) (10) Driver report Driver report 160D9V3HM31 3-104...
  • Page 154 (11) (11) Pre-check report Pre-check report 160D9V3HM32 (12) (12) Collision and over speed report Collision and over speed report 160D9V3HM33 3-105...

  • Page 155: Operator Maintenance And Care

    Do not make repairs yourself unless you are trained in lift truck repair procedures and authorized by your employer. Have a qualified mechanic make repairs using genuine HYUNDAI or HYUNDAI- approved parts. Do not operate a truck if it is in need of repair. If it is in an unsafe condition, remove the key Do not operate a truck if it is in need of repair.

  • Page 156: Functional Checks

    2) 2) FUNCTIONAL CHECKS FUNCTIONAL CHECKS Check the operation of the truck as follows. Before performing these checks, familiarize yourself with the starting, operating, and Before performing these checks, familiarize yourself with the starting, operating, and ※ shutdown procedures in Section 5 of this manual. Also, know the safety rules given in shutdown procedures in Section 5 of this manual.

  • Page 157: Suggestion For New Truck

    2. SUGGESTION FOR NEW TRUCK 2. SUGGESTION FOR NEW TRUCK It takes about 100 operation hours to enhance its designed performance. Avoid excessive Operate according to below three steps and avoid operation for initial 100 hours excessive operation for the initial 100 hours. Service meter Load Until 10 hours...

  • Page 158: Fuel Safety Practices

    3. FUEL SAFETY PRACTICES 3. FUEL SAFETY PRACTICES REFUELING DIESEL TRUCKS 100D7OM106 Stop the engine when refueling. Stop the engine when refueling. All lights and flames shall be kept at a All lights and flames shall be kept at a safe distance while refueling.

  • Page 159: Engine Oil Service Interval&Management

    4. ENGINE OIL SERVICE INTERVAL AND MANAGEMENT 4. ENGINE OIL SERVICE INTERVAL AND MANAGEMENT It is the operator's responsibility to check its condition and be sure it is safe to operate. Please check engine oil condition periodically. Daily check Daily check ·Engine oil should be checked once a day before operation.
  • Page 160 Engine oil contamination (neglecting daily and periodic check) Engine oil contamination (neglecting daily and periodic check) ① Excessive wear and seizure of turbocharger shaft bearings due to delayed oil supply to turbocharger Gelled Checking ② Excessive wear and seizure of crankshaft main bearing ③...

  • Page 161: Starting And Operating Procedures

    5. STARTING AND OPERATING PROCEDURES 5. STARTING AND OPERATING PROCEDURES 1. BEFORE OPERATING THE TRUCK 1. BEFORE OPERATING THE TRUCK Be sure that you have read and understand the information in this Operator's Manual and are trained and authorized before operating the lift truck. A lift truck can be dangerous if not used properly.

  • Page 162: Check Before Operation

    2. CHECK BEFORE OPERATION 2. CHECK BEFORE OPERATION The Occupational Safety and Health Act (OSHA) required that truck users examine their trucks before each shifts to be sure they are in safe working order. Defects when found shall be immediately reported and corrected. The truck shall be taken out of service until it has been restored to safe operating condition.

  • Page 163: Check Before Starting Engine

    CHECK FOR WATER OR OIL LEAKAGE CHECK FOR WATER OR OIL LEAKAGE Walk around your HYUNDAI truck and check for water, oil or hydraulic leakage. Examine truck for obvious damage. Check cabin, backrest, forks, mast and lift chanins for crack or obvious damage.

  • Page 164: Check Coolant Level

    3) 3) CHECK COOLANT LEVEL CHECK COOLANT LEVEL If the cooling water in the radiator reservoir tank is not within normal range when cool, add water to the MAX line. 100D9V4OM11 If antifreeze is being used, pay careful attention to the ratio of antifreeze and water when If antifreeze is being used, pay careful attention to the ratio of antifreeze and water when adding coolant.

  • Page 165: Check Fan Belt

    5) 5) CHECK FAN BELT CHECK FAN BELT An deflection method can be used to check belt tension by applying 11 kgf (25 lbf) force between the pulleys on V-belts. If the deflection is more than one belt thickness per foot of pulley center distance, the belt tension must be adjusted.

  • Page 166: Check Hydraulic Oil Level

    6) 6) INSPECTION OF COOLING FAN INSPECTION OF COOLING FAN Personal injury can result from a fan blade fail- Personal injury can result from a fan blade fail- ure. Never pull or pry on the fan. This can dam- ure. Never pull or pry on the fan. This can dam- age the fan blade and cause fan failure.
  • Page 167 9) 9) CHECK FUEL CHECK FUEL PREFILTER PREFILTER WIF (Water in fuel) warning lamp. If the warning lamp stays on, drain the water from the fuel warning prefilter. lamp Fuel prefilter Bowl Drain valve Open Close 160D9VMI20 MULTI FUNCTION SWITCH MULTI FUNCTION SWITCH Front wiper and washer switch O J Ⅰ...

  • Page 168: Seat Adjustment

    4. SEAT ADJUSTMENT 4. SEAT ADJUSTMENT 1) 1) SEAT ADJUSTMENT SEAT ADJUSTMENT The seat adjustable to fit the contours of the operator's body. It will reduce operator fatigue due to long works hours and enhance work efficiency. Grammer seat Grammer seat (1) (1) Forward/Backward adjustment (A) Forward/Backward adjustment (A)

  • Page 169: Starting From A Safe Condition

    5. STARTING FROM A SAFE CONDITION 5. STARTING FROM A SAFE CONDITION Always start from a safe condition. LOCK Before operating a lift truck, make sure that : You are safely seated in the truck. · Seat belt is buckled up. ·...

  • Page 170: General Starting And Operating Tips

    6. GENERAL STARTING AND OPERATING TIPS 6. GENERAL STARTING AND OPERATING TIPS Before you start the truck, make sure that you have taken all the above-mentioned precautions, you have read this manual, you are starting from a safe condition, with the directional control in NEUTRAL, the seat adjusted, and your seat belt buckled.

  • Page 171: Starting The Engine

    7. STARTING THE ENGINE 7. STARTING THE ENGINE START FROM A SAFE CONDITION START FROM A SAFE CONDITION Before you start the truck, safely seat yourself on the truck, fasten seat belt, apply the parking brake, make sure all controls are in neutral or other correct position, lower the forks fully to floor or ground, put the gear selector lever in NEUTRAL, and make sure you know how to operate the truck and all its controls.

  • Page 172: Check After Starting Engine

    8. CHECK AFTER STARTING ENGINE 8. CHECK AFTER STARTING ENGINE 1) 1) CHECK FOR ABNORMAL NOISE OR VIBRATION CHECK FOR ABNORMAL NOISE OR VIBRATION 2) 2) CHECK ENGINE EXHAUST GAS COLOR CHECK ENGINE EXHAUST GAS COLOR Exhaust gas color Criteria Colorless, light blue Black Check for incomplete combustion...
  • Page 173 4) 4) CHECK CLUSTER CHECK CLUSTER These lamps light up to indicate an abnormality. These lamps light up to indicate an abnormality. ※ So, if one of these lamps is lighted, take appropriate service and maintenance. So, if one of these lamps is lighted, take appropriate service and maintenance. Cluster warning lamps light up to indicate an abnormality.

  • Page 174: Warming Up Operation

    9. WARMING UP OPERATION 9. WARMING UP OPERATION The most suitable temperature for the hydraulic The most suitable temperature for the hydraulic ※ oil is about 50 oil is about 50˚C C (112 (112˚F ). F ). 5 minute warming-up It can cause serious trouble in the hydraulic It can cause serious trouble in the hydraulic s y s t e m b y s u d d e n o p e r a t i o n w h e n t h e...

  • Page 175: Levers And Pedals

    10. LEVERS AND PEDALS 10. LEVERS AND PEDALS 1) 1) POSITIONING FORKS AND MAST POSITIONING FORKS AND MAST When driving, with or without a load, it is a good practice to always raise the forks slightly and tilt the mast (forks) backward. Raising the forks and tilting them back prevents the fork tips from catching on possible obstructions and reduce the wear on the fork blades from striking or dragging on the floor or ground.
  • Page 176 2) 2) SELECTING DIRECTION OF TRAVEL SELECTING DIRECTION OF TRAVEL Push the gear selector lever forward, center it , or pull it back Forward for FORWARD, NEUTRAL, or REVERSE, respectively. Traction is disabled in NEUTRAL. Reverse 160D7OM95 3) 3) USING THE ACCELERATOR PEDAL USING THE ACCELERATOR PEDAL With the parking brake released and the gear selector lever in FORWARD or REVERSE, put your foot on the accelerator...

  • Page 177: Traveling Of The Truck

    11. TRAVELING OF THE TRUCK 11. TRAVELING OF THE TRUCK 1) 1) BASIC OPERATION BASIC OPERATION Tilt back fully (1) (1) Traveling posture Traveling posture Lift the forks so that the forks are placed 15~ 20 cm (6~8 in) above the ground and tilt back the mast fully.
  • Page 178 When traveling at high speed, do not When traveling at high speed, do not abruptly decelerate by using the gear abruptly decelerate by using the gear selector lever, to slow down instead press selector lever, to slow down instead press the brake pedal.
  • Page 179 (6) (6) Stopping the truck Stopping the truck Press the brake pedal to stop the truck. ① Parking Put the gear selector lever in the neutral ② position. Turn the parking brake switch ON. ③ Parking brake switch 100D9V5SO12 Lower the forks to the ground. ④...
  • Page 180 2) 2) TRAVELING ON A SLOPE TRAVELING ON A SLOPE Loaded Never travel down a slope in neutral. Lower the forks 15-20 cm (6~8 in) to the ground. Never turn on a slope, either loaded or unloaded. Never park on a slope. 100D9VOM33 Loaded Loaded - move with forks upgrade...

  • Page 181: Operating Safely

    12. OPERATING SAFELY 12. OPERATING SAFELY Safe operation is the responsibility of the operator. WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE... WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE... 1) 1) Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
  • Page 182 Travel with the fork carriage tilted back and raised only enough to fully clear the ground or obstacles. When the carriage (load) is in an elevated position the stability of the truck is reduced. Do not elevate the load except during stacking. 5) 5) GRADES, RAMPS, AND INCLINES...

  • Page 183: Load Handling

    13. LOAD HANDLING 13. LOAD HANDLING 1) 1) GENERAL GENERAL Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load handling attachments, load having a high center of gravity, or uneven terrain may dictate that the safe working load be less than the rated capacity.
  • Page 184 2) 2) ADJUSTING THE LOAD FORKS ADJUSTING THE LOAD FORKS The load forks are adjustable on the hanger, carriage. Forks should be spaced as far apart as the load will allow. Both forks should always be the same distance from the center of the fork carriage.
  • Page 185 4) 4) TRAVELING WITH LOAD TRAVELING WITH LOAD Travel with load or carriage as low as possible and tilted back. Never travel with the load or carriage raised (elevated) in a high position. Do not elevate the load except during stacking. Observe all traffic regulations and watch for other traffic, pedestrians, and safe clearances.
  • Page 186 5) 5) PICKING UP AND MOVING LOADS PICKING UP AND MOVING LOADS When picking up a load from the ground, approach the load slowly and carefully align the truck square with the load. The forks should be adjusted to fit the load or pallet being handle and spread as wide as possible to provide good stability and balance.
  • Page 187 7) 7) STACKING STACKING (1) (1) To put a load on a stack To put a load on a stack Aproach slowly and align the lift truck and load squarely with ① the stack. D35AOM137 Raise the load as the lift truck nears the stack. ②...
  • Page 188 (2) (2) To move a load from a stack To move a load from a stack Approach the stack carefully, truck lined up squarely with the load. With mast vertical, raise the forks to the correct height for freely engaging the load pallet. Adjust fork angle as necessary to fit squarely under the load.

  • Page 189: Shut Down Procedure

    14. SHUT DOWN PROCEDURE 14. SHUT DOWN PROCEDURE Always leave your lift truck in a safe condition. Always leave your lift truck in a safe condition. ※ 1) 1) WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFETY RULES WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFETY RULES Park in a safe area away from normal traffic.

  • Page 190: Storage

    15. STORAGE 15. STORAGE 1) 1) BEFORE STORAGE BEFORE STORAGE When you keep your forklift truck in storage for an extended period of time, observe the following safeguard instructions: Wash and tidy the truck and house it in a dry building.

  • Page 191: After Storage

    3) 3) AFTER STORAGE AFTER STORAGE After storage (When it is kept without cover or the rust-preventive operation once a month is not carried out), you should apply the following treatment before operation. Remove the drain plugs from the oil pan and other cases and drain any water. Remove the rocker housing cover and lubricate the valves and rocker arms well.

  • Page 192: Transport

    PRECAUTIONS FOR LOADING AND UNLOADING PRECAUTIONS FOR LOADING AND UNLOADING Contact your HYUNDAI forklift distributor for advice regarding transportation of the truck. When loading or unloading the truck on or from a transporter, using loading ramp, the following precautions must always be observed.

  • Page 193: Loading And Unloading By Crane

    17. LOADING AND UNLOADING BY CRANE 17. LOADING AND UNLOADING BY CRANE Check the specification of the truck when you are going to hoist the truck. Use long wire rope and stay to keep the distance Stay Wire rope with the machine as it should avoid touching with To lift the truck body.

  • Page 194: Emergency Procedures

    Check that the counterweight bolts are in place and properly torqued. (This bolt is made of a special high tensile steel and is not commercially available. Replace it, when necessary, only with a genuine HYUNDAI replacement part). Use an approved, solid metal tow bar with towing couplers that connect to the towing pins in the counterweights.
  • Page 195 Park the disabled truck in authorized areas only. Fully lower the forks to the floor, put the gear selector lever in the NEUTRAL position and turn the staring switch to the OFF position. Set the parking brake switch the ON (LOCK) position. Remove the key and, when necessary, block the wheels to prevent the truck from rolling.

  • Page 196: Parking Brake Release

    2. PARKING BRAKE RELEASE 2. PARKING BRAKE RELEASE Parking brake is operated by the spring force and released by hydraulic pressure. If the engine or transmission does not operate, the parking brake will be operated to stop the truck. For an emergency, the parking brake can be released as below. 100D7BS117 Thrust bolt Screw cap...

  • Page 197: How To Use Battery Jumper Cables

    3. HOW TO USE BATTERY JUMPER CABLES 3. HOW TO USE BATTERY JUMPER CABLES If your lift truck battery is discharged (dead), you can start your lift truck by jumping it from another lift truck that has a 12 V negative-ground electrical system. The "Booster" battery must be fully charged and in good condition.
  • Page 198 Connect the jumper cables in the following To ground sequence: To start switch ⓐ Connect a jumper cable from the positive (+; red) terminal on one battery to the positive (+; red) terminal on the other Charged battery battery. Never connect positive (+; red) to negative (-;...

  • Page 199: Emergency Fork Lowering

    4. EMERGENCY FORK LOWERING 4. EMERGENCY FORK LOWERING In case that the mast can not be lowered due to a problem in the controller, activate the emergency lowering valve on the MCV assembly by rotating the valve (a). Manual override features are intended for Manual override features are intended for emergency use, not for continuous-duty emergency use, not for continuous-duty...

  • Page 200: Key-Lowering Interlock

    5. KEY-LOWERING INTERLOCK 5. KEY-LOWERING INTERLOCK When the engine is stopped and the start key is in the 'OFF' position, the fork does not lower when the lift lever is pushed forward. However, sitting on the seat, placing the engine start key in the 'ON' position and pushing the lift lever forward allows the fork to be lowered even if the engine stops.

  • Page 201: Planned Maintenance And Lubrication

    Specifications for selected components, fuel, lubricants, critical bolt torques, refill capacities, and settings for the truck are found in section 8. If you need for more information on the care and repair of your truck, see your HYUNDAI dealer.

  • Page 202: Safe Maintenance Practices

    Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local HYUNDAI dealer. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities and trained personnel and procedures shall be provided.
  • Page 203 Before leaving the truck. Stop the truck. Fully lower the load-engaging means: mast, carriage, forks or attachments. Put the gear selector lever in NEUTRAL position. Apply the parking brake. Stop the engine. Turn the start switch to the OFF position. Put blocks at the wheels if the truck must be left on an incline.
  • Page 204 Parts, including tires, are to be installed per the manufacturer's procedures. Always use genuine HYUNDAI or HYUNDAI-approved parts. When removing tires follow industry safety practices. Most importantly, deflate pneumatic tires completely prior to removal.

  • Page 205: Instructions Before Maintenance

    3. INSTRUCTIONS BEFORE MAINTENANCE 3. INSTRUCTIONS BEFORE MAINTENANCE 1) 1) INTERVAL OF MAINTENANCE INTERVAL OF MAINTENANCE You may inspect and service the truck by the period as described at based on service meter of LCD. Shorten the interval of inspect and service depending on site condition.(Such as dusty area, quarry, sea shore and etc.) Practice the entire related details at the same...

  • Page 206: Proper Maintenance

    Engine and hydraulic components have been preset in the factory. Do not allow unauthorized personnel to reset them. Ask to your local dealer or Hyundai for maintenance advise it unknown. Drain the used oil and coolant in a container and handle according to the method of handling for industrial waste to meet with regulations of each province or country.
  • Page 207 6) 6) EMISSION-RELATED COMPONENTS WARRANTY EMISSION-RELATED COMPONENTS WARRANTY (USA AND CANADA ONLY) Hyundai shall have obligation under the EPA (Environmental Protection Agency) regulation of warranty about Emission-related components. This warranty shall exist for 3,000 hours or five years, whichever occurs first.

  • Page 208: Planned Maintenance Intervals

    4. PLANNED MAINTENANCE INTERVALS 4. PLANNED MAINTENANCE INTERVALS 1) 1) MAJOR COMPONENTS LOCATION MAJOR COMPONENTS LOCATION 9 10 11 12 100D9V7PM01 Mast Propeller shaft 17 Radiator Lift cylinder 10 Hydraulic pump 18 Air cleaner Tilt cylinder 11 Transmission 19 Precleaner Steering unit 12 Torque converter 20 Counterweight...

  • Page 209: Service Locations

    2) SERVICE LOCATIONS 2) SERVICE LOCATIONS 1, 12 50D9MA011A Service intervals are based on the hourmeter reading. Service intervals are based on the hourmeter reading. ※ Stop the engine when servicing. Stop the engine when servicing. ※ Do not open the cap or drain plug to avoid injury by unexpected spouting of high temperature Do not open the cap or drain plug to avoid injury by unexpected spouting of high temperature ※...
  • Page 210 3) 3) DAILY (OR EVERY 10 HOURS) CHECK LIST DAILY (OR EVERY 10 HOURS) CHECK LIST Item Service Capacity Service Description Remark Action symbol ℓ (U.S. gal) point Engine oil level Check, Add 12 (3.17) 7-17 Pedal linkage operation Check, Adjust 7-50 Drive rim and tire air pressure Check, Add...
  • Page 211 Fork load indicator (option) Mast tilt angle measurement Harsh condition * Normal condition * Conventional hydraulic oil * Hyundai genuine long life hydraulic oil A : Aid C : Checking L : Lubrication R : Replacement T : Retightening...
  • Page 212 Clean Hydraulic oil (5000) Harsh condition * Normal condition * Conventional hydraulic oil * Hyundai genuine long life hydraulic oil A : Aid C : Checking L : Lubrication R : Replacement T : Retightening I : Visual inspection (repair or replace if required)

  • Page 213: How To Perform Planned Maintenance

    5. HOW TO PERFORM PLANNED MAINTENANCE 5. HOW TO PERFORM PLANNED MAINTENANCE 1) 1) VISUAL INSPECTION VISUAL INSPECTION First, perform a visual inspection of the lift truck and its components. Walk around the truck and take note of any obvious damage or maintenance problems.
  • Page 214 4) 4) FORKS FORKS Inspect the load forks for cracks, breaks, bending, and wear. The fork top surfaces should be level 10% of "A" is and even with each other. The height difference max. wear between both fork tips refer to below table. allowed Fork length Height...

  • Page 215: Wheel And Tires

    6) 6) WHEEL AND TIRES WHEEL AND TIRES Check the condition of the drive and steering wheels and tires. Remove objects that are embedded in the tread. Inspect the tires for excessive wear and breaks or chunking out chunking out. Check all wheel lug nuts or bolts to be sure none are loose or missing.
  • Page 216 7) 7) TILTING CABIN TILTING CABIN Keep clearance of people except the Keep clearance of people except the operator before tilting the cabin. operator before tilting the cabin. Before tilting the cabin, make sure that the Before tilting the cabin, make sure that the mast is vertical or tilted forward.
  • Page 217 Tilting and returning cabin Tilting and returning cabin Tilting cabin Tilting cabin ① After keeping clearance of the people except the operator along with sounding horn, turn the hand pump lever clockwise and then, continuously press the cabin tilt switch to tilt the cabin to right side.

  • Page 218: Service Instruction

    6. SERVICE INSTRUCTION 6. SERVICE INSTRUCTION 1) 1) CHECK ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL Check the oil level with the truck on a flat ground Dipstick before starting engine. Pull out the dipstick and wipe with a clean cloth. Check the oil level by inserting the dipstick completely into the hole and pulling out again.
  • Page 219 Apply a light film of lubricating oil to the gasket sealing surface before installing the filter. Fill the filter with clean lubricating oil. Fill the filter with clean lubricating oil. ※ The lack of lubrication during the delay until The lack of lubrication during the delay until the filter is pumped full of the start-up can the filter is pumped full of the start-up can damage the engine.
  • Page 220 3) 3) CHECK COOLANT LEVEL CHECK COOLANT LEVEL Do not remove the surge tank cap when Do not remove the surge tank cap when Surge tank cap the engine is hot. the engine is hot. Then loosen the cap slightly to release Then loosen the cap slightly to release unwanted pressure before you remove unwanted pressure before you remove...
  • Page 221 4) 4) FLUSHING AND REFILLING OF RADIATOR FLUSHING AND REFILLING OF RADIATOR (1) (1) Change coolant Change coolant Avoid prolonged and repeated skin contact Avoid prolonged and repeated skin contact with used antifreeze. Such prolonged with used antifreeze. Such prolonged repeated contact can cause skin disorders repeated contact can cause skin disorders or other bodily injury.
  • Page 222 During filling, air must be vented from During filling, air must be vented from ※ the engine coolant passages. the engine coolant passages. The system must be filled slowly to The system must be filled slowly to prevent air locks or serious engine prevent air locks or serious engine d a m a g e c a n r e s u l t .
  • Page 223 (3) (3) Cooling system filling Cooling system filling Use a mixture of 50 percent water and ① 50 percent ethylene glycol antifreeze to fill the cooling system. Refer to page 7-60. ※ Use the correct amount of DCA4 Use the correct amount of DCA4 corrosion inhibitor to protect the corrosion inhibitor to protect the cooling system.
  • Page 224 100D9V7PM28 6) 6) CHECK CHARGE AIR COOLER CHECK CHARGE AIR COOLER Inspect the charge air cooler for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If damage is found, please contact Hyundai distributor. 100D9V7PM29 7-24...
  • Page 225 7) 7) FAN BELT TENSIONER FAN BELT TENSIONER With the engine stopped, check the tensioner arm, pulley, and stops for cracks. If any cracks are found, the tensioner must be replaced. 2609A6MA23 With the belt installed, verify that neither tension- er arm stop is in contact with the spring case stop.

  • Page 226: Air Cleaner Element

    8) 8) AIR CLEANER ELEMENT AIR CLEANER ELEMENT Clamp (1) (1) Removal Removal Outer element Double element type Double element type ① Remove the cover by pulling off the clamps, and loosen the wing nut to pull out the outer element. During periodic service, replace only During periodic service, replace only ※...

  • Page 227: Installation

    ※ Keep clean condition for the air cleaner element all the times. Keep clean condition for the air cleaner element all the times. A dirty air cleaner could be decreased output power of the engine at worst and it also will A dirty air cleaner could be decreased output power of the engine at worst and it also will be caused to increase fuel consumption and black smoke.

  • Page 228: Fuel Prefilter

    FUEL PREFILTER FUEL PREFILTER Inspect or drain the collection bowl of water Inspect or drain the collection bowl of water ※ daily and replace the element every 500 daily and replace the element every 500 hours. hours. (1) (1) Drain water Drain water Open bowl drain valve to evacuate water.
  • Page 229 REPLACEMENT OF FUEL FILTER ELEMENT REPLACEMENT OF FUEL FILTER ELEMENT Clean all around the filter area before remove Clean all around the filter area before remove ※ the fuel filter. Dirt or contaminants can the fuel filter. Dirt or contaminants can damage the fuel system.

  • Page 230: Bleeding The Fuel System

    BLEEDING THE FUEL SYSTEM BLEEDING THE FUEL SYSTEM Air vent Loosen air vent plug at the outlet of prefilter. plug Open Close Do hand-priming the lift pump repeatedly until air bubbles comes out from air vent plug hole completely. Lift pump Tighten air vent plug to its origin position.
  • Page 231 DIESEL EXHAUST FLUID DOSING UNIT DIESEL EXHAUST FLUID DOSING UNIT FILTER FILTER (1) (1) Remove Remove There may be residual DEF in the filter There may be residual DEF in the filter ※ housing. A collection container placed below housing. A collection container placed below the DEF filter cap is recommended.
  • Page 232 Clean the aftertreatment DEF dosing unit cap ④ and threads on the dosing unit with warm water and a clean cloth. Never operate the truck with the DEF cap Never operate the truck with the DEF cap ※ removed. removed. 250D9DEF03 (3) (3) Install...
  • Page 233 DEF/AdBlue® SUPPLY MODULE FILTER DEF/AdBlue® SUPPLY MODULE FILTER Inspect the area around the DEF/AdBlue® sup- ply module filter case for signs of leakage. Turn OFF the master switch mounted electric Turn OFF the master switch mounted electric ※ box. box. Filter kit tank 160D9VMA95...
  • Page 234 If the DEF/AdBlue ® level is found to below, DEF/ AdBlue ® must be added. Before filling the tank Before filling the tank Switch off the engine. ① Secure the truck against rolling away. Always fill ② the tank with at least 5 liters, as smaller amounts could cause malfuctions.

  • Page 235: Hydraulic Oil Check

    Place the filter cover and rotate the cover clockwise by using hex wrench. Replace the filter every 2000 hours. Replace the filter every 2000 hours. ※ If the filter is reused, take care not to damage If the filter is reused, take care not to damage ※...

  • Page 236: Filling Hydraulic Oil

    FILLING HYDRAULIC OIL FILLING HYDRAULIC OIL Air breather Stop the engine to the position of level check. Check air breather element and replace it if necessary. Bolt Loosen cap and fill the oil to the specified level. Cover Start engine after filling and operate the work Element equipment several times.
  • Page 237 REPLACEMENT OF THE SUCTION STRAINER REPLACEMENT OF THE SUCTION STRAINER Tank flange Remove the tank flange by loosening the Bolt mounting bolt. Remove the suction strainer from the tank. Replace the suction strainer with a new one. Suction strainer Install the flange on the tank. ·...
  • Page 238 CLEANING THE LINE FILTER CLEANING THE LINE FILTER Cutoff valve Relieve the pressure in the brake system by pushing the brake pedal 2~3 times with starting switch ON position. Remove the line filter from the cutoff valve. Flow Loosen the cap (f). Remove the element (c).
  • Page 239 Model Size Pressure Normal 100D-9V 9.00-20-14PR 7.5 kgf/cm (110 psi) Continuous operation will produce heat and i n c r e a s e p r e s s u r e o n t i r e . B u t s u c h phenomenon was already taken into account when designing a tire.

  • Page 240: Replacement Of Tire

    Do not use recycled wheel parts. Do not use recycled wheel parts. When removing lockering or inflating tire, use When removing lockering or inflating tire, use safety cable or chain to ensure safety. safety cable or chain to ensure safety. B e s u r e t o b l e e d a i r b e f o r e r e m o v i n g B e s u r e t o b l e e d a i r b e f o r e r e m o v i n g lockering.
  • Page 241 Loosen slightly all wheel mounting. ② ·Tools : Socket 32mm Torque wrench Extension bar Lift the truck with a jack. ③ Loosen all wheel mounting nuts and replace ④ the tire. Torque wrench 160D7MI37 (3) (3) Direction of tire to be installed Direction of tire to be installed Be careful that the valve should be facing the ①...

  • Page 242: Check Transmission Oil Level

    CHECK TRANSMISSION OIL LEVEL CHECK TRANSMISSION OIL LEVEL Dipstick The oil level check must be carried out as follows; Oil level check (weekly). At horizontally standing the truck. Transmission in neutral position. In cold start phase, the engine must be running about 2~3 minutes at idling speed, and the marking on the oil dipstick must then be lying above the cold start mark COLD.
  • Page 243 Remove the transmission oil filter. Dispose of the used transmission oil filter properly. Clean the filter mounting base. Remove any part of the filter gasket that remains on the filter mounting base. Transmission oil filter 100D9V7PM52 Apply a light coat of oil to the gasket of a new transmission oil filter.
  • Page 244 CLEANING TRANSMISSION AIR BREATHER CLEANING TRANSMISSION AIR BREATHER Air breather Remove dust or debris around the air breather. Remove the air breather and wash it with the cleaning oil. 100D9V7PM53 CHECK AND SUPPLYING AXLE OIL CHECK AND SUPPLYING AXLE OIL Move the truck to flat ground.
  • Page 245 If the oil level is below the plug hole, supply oil Planetary gear through a plug hole. When checking the oil level, engage the When checking the oil level, engage the parking brake and fix the tires with blocks. parking brake and fix the tires with blocks. Plug As the truck is hot after operation, wait until As the truck is hot after operation, wait until...
  • Page 246 Supply oil into the differential gear and the Differential gear planetary gear. ·Oil amount : 13ℓ(3.43 U.S. gal) Supply oil until it overflows from the oil filler, then install the plug. As the truck is hot after operation, wait until As the truck is hot after operation, wait until the temperature has dropped.
  • Page 247 BRAKE BRAKE COOLING OIL AND STRAINER COOLING OIL AND STRAINER Tank cap Check the oil level. If oil level is near or under the lower limit, add oil immediately. Frame - RH side Change oil and strainer completely every 1000 hours operation.

  • Page 248: Fork Replacement

    LUBRICATION LUBRICATION Supply grease through the grease nipple, using the grease gun. After lubricating, clean off spilled grease. Apply the parking brake and fix the front and Apply the parking brake and fix the front and rear tires with blocks. rear tires with blocks.
  • Page 249 MAINTENANCE OF WORK EQUIPMENT MAINTENANCE OF WORK EQUIPMENT Lubricate to each point of working device. Lubricate the grease to grease nipple in accordance with lubrication intervals. Description Fork adjustment cylinder pin Fork shaft Tilt cylinder pin Load chain Mast support pin Chain sheave pin Shorten lubricating interval when working in the Shorten lubricating interval when working in the...

  • Page 250: Electrical System

    7. ELECTRICAL SYSTEM 7. ELECTRICAL SYSTEM 1) 1) WIRING, GAUGES WIRING, GAUGES C h e c k r e g u l a r l y a n d r e p a i r l o o s e o r malfunctioning gauges when found.

  • Page 251: Air Conditioner And Heater

    8. AIR CONDITIONER AND HEATER 8. AIR CONDITIONER AND HEATER 1) 1) CLEANING AND REPLACING FILTER CLEANING AND REPLACING FILTER Always stop the engine before servicing. Always stop the engine before servicing. ※ Open the door, loosen the wing bolt and remove the recircular plenum assembly.
  • Page 252 (1) (1) Equipment contains fluorinated greenhouse gas. Equipment contains fluorinated greenhouse gas. Model Type Quantity 100D-9V HFC-134a 0.55 kg (1.21 lb) 787 CO ※ Global warming potential (GWP) is a measure of how much heat a gas traps in the atmosphere relative to that of carbon dioxide (CO2).

  • Page 253: Replacement And Check

    9. REPLACEMENT AND CHECK 9. REPLACEMENT AND CHECK 1) 1) WIRING, GAUGES WIRING, GAUGES Check regularly and repair the loose or malfunc- tioning gauges when found. 13036MI29 2) 2) BATTERY BATTERY Clean Clean (1) (1) Wash the terminal with hot water if it is ①...

  • Page 254: Transmission Oil

    Prior to reinstall the cable, inspect in detail and Prior to reinstall the cable, inspect in detail and Connect (-) lead last confirm the condition of the cables and replace confirm the condition of the cables and replace it when the cables possess any kind of it when the cables possess any kind of Neg(-) abnormal damages such as cracking and wear...

  • Page 255: Cooling System

    4) 4) COOLING SYSTEM COOLING SYSTEM (1) (1) Radiator fins cleaning Radiator fins cleaning Remove dust between the radiator fins with compressed air. The steam or water may be used instead of compressed air. Air pressure should be less than 2 kgf/cm kPa (30 psi).

  • Page 256: Tire Replacement

    For details of procedures, contact your HYUNDAI dealer. Wear safety glasses and a face shield when using compressed air. your HYUNDAI dealer. Wear safety glasses and a face shield when using compressed air.
  • Page 257 6) 6) FUSE AND RELAY REPLACEMENT FUSE AND RELAY REPLACEMENT (1) (1) Fuse box Fuse box AIRCON B+/ HORN/ STOP/ RMCU/ DEF SUPPLY DEF LINE ROOM LAMP CLUSTER POW.IND COVER P/N : 2YFJ-15852 CAB TILT TURN LAMP MONITOR SENSOR MODULE /RADIO HEATER AIRCON...

  • Page 258: Functional Tests

    7) 7) LAMP BULBS REPLACEMENT LAMP BULBS REPLACEMENT Lamp Spec (12 V) Head and turn signal lamp Clearance lamp Stop lamp Backup lamp Room lamp 10 W License lamp (option) Beacon lamp (option) LED strobe type 70D9V7PM21 Rear work lamp (option) After checking that the fuse is not blown and that there is no disconnection in the wiring After checking that the fuse is not blown and that there is no disconnection in the wiring harness, replace the lamp bulb.
  • Page 259 (5) (5) Parking brake Parking brake Check the function of the parking brake. Release, then reapply. To check parking brake holding capability, park the lift truck on a grade and apply the parking brake. The parking brake should hold a lift truck with rated load on a 15% grade. Do not operate a lift truck if the service or parking brakes are not operating properly.
  • Page 260 (8) (8) Steering system Steering system The steering system, steering axle, and steering linkage on your truck should be inspected The steering system, steering axle, and steering linkage on your truck should be inspected ※ periodically for abnormal looseness and damage, leaking seals, etc.. Also, be alert for any periodically for abnormal looseness and damage, leaking seals, etc..
  • Page 261 Inspect the battery for damage, cracks, leaking condition, etc.. If the terminals are corroded, clean and protect them with HYUNDAI battery saver(Available from your HYUNDAI dealer). EXPLOSIVE GASES : Do not smoke or have open flames or sparks near the batteries. An EXPLOSIVE GASES : Do not smoke or have open flames or sparks near the batteries.
  • Page 262 OIL PERFORMANCE DESIGNATION: To help achieve proper engine performance and durability, use only engine lubricating oils of the proper quality. For the diesel engines, HYUNDAI recommends that you use motor oil that meets API service classification CK-4 or better for the diesel engines.
  • Page 263 Clean the fittings and lubricate the tilt cylinder rod end bushings (forward end) and both the base rod-end bushings (rear end). Clean and lubricate the mast support bushings. (3) (3) Lift chains Lift chains Lubricate the entire length of the mast rail lift and carriage chains with HYUNDAI chain and cable lube. 7-63...

  • Page 264: Air Cleaning

    AIR CLEANING AIR CLEANING Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint, or other contaminants to accumulate on the truck. Keep the truck free from leaking oil and grease. Wipe up all oil spills. Keep the controls and floorboards clean, dry, and safe.
  • Page 265 HYUNDAI chain lubricant is recommended; it is easily sprayed on and provides superior lubrication. Heavy motor oil may also be used as a lubricant and corrosion inhibitor.

  • Page 266: Handling Truck In Extremely Hot Places

    10. HANDLING TRUCK IN EXTREMELY HOT PLACES 10. HANDLING TRUCK IN EXTREMELY HOT PLACES Pay careful attention particularly to the following points when handling the truck in extremely hot Radiator places. Compressed Scale and rust form more easily in the cooling air gun system, so wash with anticorrosion liquid.

  • Page 267: Cold Weather Operation

    11. COLD WEATHER OPERATION 11. COLD WEATHER OPERATION 1) 1) PREPARATION FOR LOW TEMPERATURE PREPARATION FOR LOW TEMPERATURE Replace lubrication oil with oil of the prescribed Min ambient temperature -5 -10 -15 -20 -25 -30 -50 viscosity. (˚C ) Fuel of low pour point must be used. ASTM Amount of D975 No.1 diesel fuel should be used at 25 30 35 40 45 50 60...

  • Page 268: Recommendation Table For Lubricants

    HD HYUNDAI OIL BANK Xteer THF 75W-80 Axle oil SAE 80W-90 Brake cooling oil HD HYUNDAI OIL BANK Xteer THF 75W-80 ISO VG32/VG46/VG68, Hyundai genuine long life hydraulic oil Hydraulic oil ★1 ISO VG15, Conventional hydraulic oil Grease Lithium base grease NLGI No.2 ★2...

  • Page 269: Fuel And Lubricants

    SAE 10W Engine oil SAE 10W-30 Engine oil 12 (3.17) SAE 5W-30 SAE 15W-40 SAE 30 Torque Transmission HD HYUNDAI OIL BANK Xteer THF 75W-80 converter 18 (4.8) transmission Axle Gear oil 13 (3.43) SAE 80W-90 Brake Cooling oil 22 (5.8) HD HYUNDAI OIL BANK Xteer THF 75W-80 ★...

  • Page 270: Specifications

    8. SPECIFICATIONS 8. SPECIFICATIONS 1. SPECIFICATION TABLE 1. SPECIFICATION TABLE 100D9V8SP01 Model Unit 100D-9V Capacity kg (lb) 10000 (22000) Load center mm (in) 600 (24") Weight(Unloaded) kg (lb) 13125 (28936) Lifting height mm (ft · in) 3025 (9' 11") Free lift mm (in) 150 (5.9)

  • Page 271: Specification For Major Components

    2. SPECIFICATION FOR MAJOR COMPONENTS 2. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Unit Specification Model Cummins F3.8 Type Vertical, 4 cycle DI, EU Stage V diesel engine Cooling Method Water cooling Number of cylinders and arrangement 4 cylinders, In-line Firing order 1-3-4-2 Combustion chamber type...

  • Page 272: Steering Unit

    (lbf) 3 spool : 28 (61.7), 4 spool : 36 (79.4), 5 spool : 43 (94.8) 4) 4) STEERING UNIT STEERING UNIT Specification Item Unit 100D-9V Type Load sensing Model VSP 200 LSH Capacity 200 (12.2) cc/rev (in /rev)
  • Page 273 6) 6) POWER TRAIN DEVICE POWER TRAIN DEVICE Specification Item 100D-9V Type 3 Element, 1 stage, 2 phases Torque converter Stall ratio 2.395 : 1 Model ZF 3WG94 Type Full auto, power shift Gear shift (F/R) Transmission Adjustment Electrical single lever type 1 : 4.714...

  • Page 274: Tightening Torque

    3. TIGHTENING TORQUE 3. TIGHTENING TORQUE Item Size kgf·m lbf·ft Engine mounting bolt M12×1.25 12.3±3.0 89±21.7 Engine Engine bracket mounting nut M10×1.5 6.9±1.4 50±10.1 Radiator mounting bolt, nut M10×1.5 6.9±1.4 50±10.1 Hydraulic pump mounting bolt M16×2.0 19±2 138±14.5 MCV mounting bolt M 8×1.25 2.5±0.5 18±3.6...

  • Page 275: Troubleshooting

    9 . TROUBLESHOOTING 9 . TROUBLESHOOTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM Trouble symptom Probable cause Remedy Oil pressure warning lamp ·Low oil level in oil pan. ·Add oil. fails to go out. ·Oil filter element clogged. ·Replace element. ·Loose or worn oil pipe joint leaks oil. ·Check and repair.

  • Page 276: Electrical System

    2. ELECTRICAL SYSTEM 2. ELECTRICAL SYSTEM Trouble symptom Probable cause Remedy Lamps dimming even at maxi- ·Faulty wiring. ·Check for loose terminal and discon- mum engine speed. nected wire. Lamps flicker during engine ·Improper belt tension. ·Adjust belt tension. operation. Charge lamp does light during ·Charge lamp defective.

  • Page 277: Torque Flow System

    3. TORQUE FLOW SYSTEM 3. TORQUE FLOW SYSTEM Trouble symptom Probable cause Remedy 1. Excessive oil temperature rise ·Improper oil level. ·Check oil level. Add or drain oil as 1) Torque converter necessary. ·Impeller interfering with surroundings. ·After draining oil from oil tank and transmission, check and replace interfering parts.
  • Page 278 Trouble symptom Probable cause Remedy 3.Low output power 1) Torque converter ·Insufficient hydraulic pressure : - Low oil level. - Check oil level and add oil - Air sucked in. - Check joints and pipes. If necessary, retighten joint or repla- ce packing.
  • Page 279 Trouble symptom Probable cause Remedy 4.Unusual oil pressure 1) Oil pressure is high ·Control valve malfunctioning. (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. If necessary, clean or repair. ·Cold weather. (high oil viscosity) ·When atmospheric temp is below fr- eezing point (when normal oil pressure is recover-...
  • Page 280 Trouble symptom Probable cause Remedy 5. Power is not transmitted ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or (Continue) age to clutch. replace. ·Shaft spline worn. ·Disassemble, check and replace. 6. Oil leakage ·Oil leaks from oil seal. ·Disassemble and check for wear of (Transmission and torque seal lips and mating sliding surfaces...

  • Page 281: Steering System

    4. STEERING SYSTEM 4. STEERING SYSTEM Trouble symptom Probable cause Remedy 1. Steering wheel drags. ·Low oil pressure. ·Check locknut. Repair. ·Bearing faulty. ·Clean or replace. ·Spring spool faulty. ·Clean or replace. ·Reaction plunger faulty. ·Replace. ·Ball-and-screw assembly faulty. ·Clean or replace. ·Sector shaft adjusting screw excessi- ·Adjust.

  • Page 282: Brake System

    5. BRAKE SYSTEM 5. BRAKE SYSTEM Trouble symptom Probable cause Remedy 1. Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil. ·Hydraulic system sucks air. ·Bleed air. ·Disk worn. ·Replace ·Brake valve malfunctioning ·Repair or replace. ·Hydraulic system clogged ·Clean.

  • Page 283: Hydraulic System

    6. HYDRAULIC SYSTEM 6. HYDRAULIC SYSTEM Trouble symptom Probable cause Remedy 1. Large fork lowering speed. ·Seal inside control valve defective. ·Replace spool or valve body. ·Oil leaks from joint or hose. ·Replace. ·Seal inside cylinder defective. ·Replace packing. 2. Large spontaneous tilt of ·Tilting backward : Check valve defec- ·Clean or replace.

  • Page 284: Mast And Fork

    7. MAST AND FORK 7. MAST AND FORK 1) 1) MAST MAST Problem Problem Cause Cause Remedy Remedy Forks fail to lower. ·Deformed mast or carriage. ·Disassemble, repair or replace. Fork fails to elevate ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump and cylinders in section 6, hydraulic system.
  • Page 285 2) 2) FORKS FORKS Problem Problem Cause Cause Remedy Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear and reduces the thickness of the wear limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion...

  • Page 286: Testing And Adjusting

    10. TESTING AND ADJUSTING 10. TESTING AND ADJUSTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM 1) 1) EASE OF STARTING, NOISE EASE OF STARTING, NOISE Set gear selector lever at NEUTRAL. Forward Neutral Backward 160D9VOM95 Turn the parking brake switch ON. Turn ON start switch, automatically heat- ing operated.

  • Page 287: Maintenance And Lubrication

    (refer to 7.PLANNED Fuel filter MAINTENANCE AND LUBRICATION). element Always use HYUNDAI Forklift genuine parts when replacing the element. After replacing the element, run the engine and check for oil leakage from the filter mount.
  • Page 288 8) 8) CHECK FAN BELT TENSION CHECK FAN BELT TENSION An deflection method can be used to check belt tension by applying 11 kgf (25 lbf) force between the pulleys on V-belts. If the deflection is more than one belt thickness per foot of pulley center distance, the belt tension must be adjusted.

  • Page 289: Drive System

    2. DRIVE SYSTEM 2. DRIVE SYSTEM 1) 1) GEAR GEAR SELECTOR SELECTOR LEVER LEVER (1) (1) Neutral starting Neutral starting Engine can be started only when the shifting lever is in neutral position. (2) (2) Shifting FWD/REV Shifting FWD/REV Forward ①...
  • Page 290 ADJUSTMENT OF THE B ADJUSTMENT OF THE BRAKE AND INCHING PEDAL RAKE AND INCHING PEDAL Inching pedal Brake pedal 70D9V10TA01 Brake stopper bolt Inching stopper bolt Inching sensor Brake storke limit bolt Brake&inching pedal interlock bolt (1) (1) Brake pedal Brake pedal ·...

  • Page 291: Travel System

    3. TRAVEL SYSTEM 3. TRAVEL SYSTEM TIRES TIRES Check tire pressure using tire gauge : SEE page 5-3 CHECK BEFORE STARTING ENGINE. Check visually for cracks and damage to tread and side wall. If crack or damage is serious, replace tire. Wear Measure tread of pneumatic tires(tires with air).

  • Page 292: Steering System

    4. STEERING SYSTEM 4. STEERING SYSTEM STEERING WHEEL STEERING WHEEL Set rear wheels facing straight forward, 30~60mm (1.2~2.4 in) then turn steering wheel to left and right. Measure range of steering wheel movement before rear wheel starts to move. Range should be 30 ~ 60 mm at rim of steering wheel.

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